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Topics - afk

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1
Printed Circuit Board / PCB etching, DIY (chemistry mostly)
« on: April 11, 2017, 01:45:02 PM »
Hi guys,

Not so relevant to our usual high voltage stuffs, I'd like to consult you about etching PCB via chemical process (which is cheap!)

Though I'm not really good with chemistry, luckily for PCB etching it is not about organic chemistry (yay).

I am using Copper (II) Chloride solution by using Hydrochloric Acid taking copper directly from the board, with hydrogen peroxide as oxidizer. As you know, CuCl2 takes copper from the board to become Cupric Chloride. This solution can be reusable by bubbling air (oxygen) into the solution with more Hydrochloric Acid, turning CuCl back to CuCl2.

However, the etching speed is really slow. It took me 10 hours to clear up around 9 cm² of copper, which is so darn long. I even had to heat the solution up but it did not speed up much. On the copper tracks that needs removing, it turns dark-colored and it seems that I have to rub them off to speed up the etching (I suspect this is copper oxide that is resulted from copper and peroxide, but it is strange as it isn't solved by acid). It is very time-consuming and inconvenient. Even worse, the longer I leave the PCB in, the chemicals will start to attack the part that I don't want to be removed.

I don't etch PCB much, but I sometimes have to do it, so I need to improve my solution for my future usage. Some DIY sites don't have much information to solve this problem for me; their etching speed doesn't look this long.

Anyone here can help me with this problem?

2
Electronic circuits / Royer induction heater
« on: April 09, 2017, 04:57:35 AM »
I HAVE REWORKED THE CIRCUIT PLEASE CLICK ON THIS LINK TO HEAD TO THE NEWEST CIRCUIT: https://highvoltageforum.net/index.php?topic=46.msg540#msg540

Hi guys,

First time coming here, though I have been in Kaizerpowerelectronics blog before.

Since it will be pointless to make another thread just for the same induction heater, I'm borrowing kamelryttarn's thread to post about my machine. If you don't mind, that is (I'll do another thread if you do mind).

First of all I have to thanks Mads for his advice on using multiple pairs of MOSFETS to deal with high-power circuit. I have made a prototype, and it worked out well:


However, the consumption rate is bad. Even at no load, it consumed approx. 16A for 15.7V input (dropped from 18V). When I put a screwdriver in, the input current rose to  17.47A. Putting in a piece of stainless steel (3x6 cm²) it became 24A. Basically, the wasted energy into heat is just too big.

I assumed that the soldered joints and copper traces burn out a lot of energy, so I decided to redo the circuit (simpler, and wider traces for high-load). Also, getting a bigger work coil.

But for this time, it does not oscillate. I fried 3/4 MOSFETs when it failed to oscillate, and had to redo the circuit (again). Still no oscillation. Just in case, I only make the newest circuit to run under voltage for around a few seconds to observe the problem.

It seems that the input voltage has dropped very low, around 7.5V (from 18V) at 20A consumption. Something must happen badly with the power supply, so I'm posting it all here as well.

The transformer is one I wound by myself. It is very big (enough to be put inside a computer case) and personally I think it can support at least 2kW:

Little final touch:


Assembled with rectifier diodes. You can see below the two square components (the bridge rectifiers) that can deal 1kV-50A each. I used two so that it can work well to 100A (I'm using the transformer at 40A as my aim, btw). To protect the transformer I also added a 20A anti-leakage circuit breaker for the primary coil.


Basically I'm confident that my transformer can support a lot of current even for 18V secondary. I'm, however, doubting the filter I used.

I'm using capacitor-input filter (pi-filter with 1 capacitor bank + 1 coil + 1 capacitor bank) to increase the filtering efficiency. You can see the big-ass coil of 48mH underneath the capacitor bank (actually two banks of around 7000µF each I combined on one circuit board).


I assume that with bigger coil the circuit will need stronger power spike to start up, and with that it overloaded the filter. Do you think that it is the case with mine?

EDIT: To OP: Where did you buy (or find) the choke? I'm trying to find a big one like that but it is hard to get one. If you bought it, how much did it cost? And btw, you are using the two chokes in the induction heater, or they are for the power supply?

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